Web offset lug dry-stack system

ABSTRACT

A means to dry stack structural concrete block walls load bearing and non-load bearing) providing improved structural strength by grouting—especially partially grouting techniques and providing no web interference even in stack bonded configurations. Instead of having concrete block cells of different sizes—one on top of the other from one course to the next—during the dry-stacking process, the invention provides for the cells (cores) of the blocks to line up perfectly to provide a well defined column for concrete grout . . . making it easier, faster . . . and technically superior to the current mortarless systems using raised lugs (and other known methods) for face shell alignment. The improved cell (core) alignment is provided in both running bond and stack bonded dry-stack construction methods.

RELATED APPLICATIONS

The present application is a continuation-in-part application of U.S. provisional patent application Ser. No. 60/529,457, filed Dec. 12, 2003, by Alan Corbett Ferguson, included by reference herein and for which benefit of the priority date is hereby claimed.

FIELD OF THE INVENTION

The present invention relates to dry-stack concrete masonry system for building stuctural load bearing and non-loadbearing walls and, more particularly, two distinct concrete masonry units with a web offset lug design that provides for both stack bonding and running bond construction with unobstructed vertical cell alignment to facilitate both solid and partial concrete grouting (for structural strength) with and without steel reinforcement.

BACKGROUND OF THE INVENTION

The key advantage of mortarless masonry systems is that the labor component to install can be dramatically reduced. Some studies have showed that mortarless masonry systems are up to 10 times faster to install than conventional mortared masonry systems. Because these systems do not use bonding mortar to provide structural support it is imperative that other means of developing wall strength be used. A viable technique to develop wall strength is to pour wet concrete grout) into the openings of the block (cores) to form vertical posts that are almost always reinforced with steel (rebar). The problem with many mortarless block systems (and especially those that do not require a core-puller to produce) is that when dry-stacked, the cells (or core holes) of the block do not line up very well . . . or the cells are of different sizes which provides little or no damming capacity when partially grouting a completed wall structure. Many dry-stack mortarless block systems require lugs that project above the top surface of the block by a 3/8 inch or more . . . these lugs tend to limit where block can be stacked in relation to one another. In order to provide structural integrity, dry-stacked concrete block walls must be filled (solid or partially) with grout to meet various building codes. The wet concrete grout is poured into the open cells of the concrete block . . . sometimes all the cells are filled (grouted solid) or sometimes the grout is poured into distinct vertical columns down only certain cells/cores of the block (partially grouted) . . . generally on 4′ centers and at wall corners and jambs of windows and doors.

A good general overview of the use of current dry stack methods in masonry wall construction can be found in NCMA National Concrete Masonry Association) technical publication TEK 14-22 “Design and Construction of Dry-Stack Masonry Walls”.

The present dry stack/mortarless wall systems used in building construction for load bearing and non-loadbearing that incorporate raised lugs for alignment and interlocking do not provide adequate or uniform core orientation. The prior art for raised lug systems has been well documented by Ivany in U.S. Pat. No. 3,968,615 . . . by Cook in U.S. Pat. No. 4,182,089 . . . by Haener in U.S. Pat. No. 4,640,071. The shortcoming of all of these inventions is the inability of the block when stacked in a running bond (one block resting on top of two halves of lower adjacent blocks) configuration to provide for a uniform and well aligned core (from bottom of wall to top of wall) for grouting . . . in addition, prior art does not allow for the stacking of block in a stack bonded configuration (one block resting completely on top of a lower adjacent block) because of the interference problem with the raised lugs.

It is therefore an object of the invention to provide an improved dry-stack concrete masonry unit (CMU) for constructing masonry load bearing and non-loadbearing wall assemblies.

It is another object of the invention to allow for improved core alignment from bottom to top of wall construction.

It is another object of the invention to make partial grouting easier and stronger.

It is another object of the invention to make structural steel reinforcement of wall assembly easier and faster.

It is another object of the invention to allow the installer to construct in both a running bond and stack bonded orientations.

SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided a means to dry stack concrete block providing improved structural strength by grouting—especially partially grouting techniques and providing no web interference even in stack bonded configurations. Instead of having concrete block cells of different sizes—one on top of the other from one course to the next—during the dry-stacking process, the invention provides for the cells of the blocks to line up perfectly to provide a well defined column for concrete grout . . . making it easier, faster . . . and technically superior to the current mortarless systems using raised lugs and other known methods) for face shell alignment. The improved cell alignment is provided in both running bond and stack bonded dry-stack construction techniques.

BRIEF DESCRIPTION OF THE DRAWINGS

A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when considered in conjunction with the subsequent, detailed description, in which:

FIG. 1 is a perspective view of a the two dry-stack units . . . the stretcher unit and the corner unit shown here assembled into a wall structure turning a 90 degree corner;

FIG. 2 is a perspective view of a FIG. 2 is a perspective view of a wall assembly showing the ability of the corner unit to be included with the stretcher units to construct a wall . . . note the chamfered/bevelled edges (at the top and sides of the units) giving the dry-stack block a classic mortared look;

FIG. 3 is a top and end view of a the web offset lug dry-stack block showing the lugs at the ends of the webs to provide for the lug offset . . . webs are at an atypical non-right angle to the face shells of the block;

FIG. 4 is a top and end view of a the web offset lugs located adjacent to the webs oriented at right angles to the unit's face shells;

FIG. 5 is an isometric view of a the dry-stack stretcher unit . . . dimensions of the block may be adjusted to meet size and thickness requirements of the particular application . . . FIG. 5 shows an 8×8×16″ block that provides for a ⅜″ bevel that imitates a mortared joint. At a dimension of 7⅝″ thickness (measured from outer face shell to outer face shell) then the block can be used in conjuction with a standard/conventional mortared 8×8×16″ masonry unit;

FIG. 6 is an isometric view of a the universal corner unit that is used with the stretcher unit to turn right angles in wall constructions . . . dimensions of the block may be adjusted to meet size and thickness requirements;

FIG. 7 is a top and front section view of a the invention showing the block cores lining up perfectly row upon row when stacked in a running bond orientation . . . shading shows where the wet concrete grout is poured and retained by the invention;

FIG. 8 is a top and front section view of a typical prior art dry stack block showing the stacked rows of block cores with incongruent (thick and thin) levels of structural grout (shaded area) . . . making it harder to insert steel reinforcement (rebar) and lowering the overall strength of the grouted section; and

FIG. 9 is a perspective view of a the invention showing how the web offset lug design provides for stacking one block on top of another in a stack bonded fashion. By rotating every other row of block 180 degrees the lugs do not interfere with each other thus allowing easy and stable stacking of the block. This ability to be stack bonded also facilitate the packaging/palletizing and shipping of the building units.

For purposes of clarity and brevity, like elements and components will bear the same designations and numbering throughout the FIGURES.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 is a perspective view of a FIG. 1 is a perspective view of the two dry-stack units . . . the stretcher unit and the corner unit shown here assembled into a wall structure turning a 90 degree corner.

FIG. 2 is a perspective view of a FIG. 2 is a perspective view of a wall assembly showing the ability of the corner unit to be included with the stretcher units to construct a wall . . . note the chamfered edges (at the top and sides of the units) give the dry-stack block a classic mortared look.

FIG. 3 is a top and end view of a FIG. 3 is a top and end view of the web offset lug dry-stack block showing the lugs at the ends of the webs to provide for the lug offset . . . webs are at an atypical non-right angle to the face shells of the block.

FIG. 4 is a top and end view of a FIG. 4 is a top and end view of the web offset lugs located adjacent to the webs oriented at right angles to the unit's face shells.

FIG. 5 is an isometric view of a FIG. 5 is an isometric view of the dry-stack stretcher unit.

FIG. 6 is an isometric view of a FIG. 6 is an isometric view of the universal corner unit that is used with the stretcher unit to turn right angles in wall constructions.

FIG. 7 is a top and front section view of a FIG. 7 is a top and front section view of invention showing the block cores lining up perfectly row upon row when stacked in a running bond orientation . . . shading shows where the wet concrete grout is poured and retained by the invention.

FIG. 8 is a top and front section view of a FIG. 8 is a top and front section view of a typical prior art dry stack block showing the stacked rows of block cores with incongruent (thick and thin) levels of structural grout (shaded area).

Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention.

Having thus described the invention, what is desired to be protected by Letters Patent is presented in the subsequently appended claims. 

1. A web offset lug dry-stack system for a dry-stack structural building system for constructing masonry walls without the use of mortar with improved construction flexibility and structural strength. comprising: means for the function of this element is to provide alignment of the building blocks as they are stacked one row at a time until the appropriate wall height is reached. the raised lugs are located as an extension to the web at an angle (other than 90 degrees) to the face shells. the angle will vary based on the thickness of the block (face shell to face shell dimension) but is such that when the blocks are stacked the web of the lower and upper row of blocks forming a wall do not interfere with one another; means for the function of this element is the same as in web offset lug option a except that the raised lug is located adjacent to the web of the block that attaches and separates the two face shells of the block; means for the function of this element is to provide for easy interlocked stacking of building units one on top of the other so that the face shells of the wall are in alignment . . . also provides stability keeping the block from rotating or sliding in relation to one another . . . shape of the lug profile may be curved or angled . . . the lug may be raised from; and means for the function of this element is to provide a additional clearance between the web of the block in the course below and the web of the block in the course above in a wall construction. the total thickness of the recess or indent is in the order of ¼″ generally starting out as a radius at the inside edge of one face shell to the inside edge of the opposite face shell's inside edge.
 2. The web offset lug dry-stack system in accordance with claim 1, wherein said means for the function of this element is to provide alignment of the building blocks as they are stacked one row at a time until the appropriate wall height is reached. the raised lugs are located as an extension to the web at an angle (other than 90 degrees) to the face shells. the angle will vary based on the thickness of the block (face shell to face shell dimension) but is such that when the blocks are stacked the web of the lower and upper row of blocks forming a wall do not interfere with one another. comprises a web offset lug option a.
 3. The web offset lug dry-stack system in accordance with claim 1, wherein said means for the function of this element is the same as in web offset lug option a except that the raised lug is located adjacent to the web of the block that attaches and separates the two face shells of the block comprises a web offset lug option b.
 4. The web offset lug dry-stack system in accordance with claim 1, wherein said means for the function of this element is to provide for easy interlocked stacking of building units one on top of the other so that the face shells of the wall are in alignment . . . also provides stability keeping the block from rotating or sliding in relation to one another . . . shape of the lug profile may be curved or angled. the lug may be raised from comprises a lug detail.
 5. The web offset lug dry-stack system in accordance with claim 1, wherein said means for the function of this element is to provide a additional clearance between the web of the block in the course below and the web of the block in the course above in a wall construction. the total thickness of the recess or indent is in the order of ¼″ generally starting out as a radius at the inside edge of one face shell to the inside edge of the opposite face shell's inside edge. comprises a web recess.
 6. A web offset lug dry-stack system for a dry-stack structural building system for constructing masonry walls without the use of mortar with improved construction flexibility and structural strength. comprising: a web offset lug option a, for the function of this element is to provide alignment of the building blocks as they are stacked one row at a time until the appropriate wall height is reached. the raised lugs are located as an extension to the web at an angle (other than 90 degrees) to the face shells. the angle will vary based on the thickness of the block (face shell to face shell dimension) but is such that when the blocks are stacked the web of the lower and upper row of blocks forming a wall do not interfere with one another; a web offset lug option b, for the function of this element is the same as in web offset lug option a except that the raised lug is located adjacent to the web of the block that attaches and separates the two face shells of the block; a lug detail, for the function of this element is to provide for easy interlocked stacking of building units one on top of the other so that the face shells of the wall are in alignment . . . also provides stability keeping the block from rotating or sliding in relation to one another . . . shape of the lug profile may be curved or angled . . . the lug may be raised from; and a web recess, for the function of this element is to provide a additional clearance between the web of the block in the course below and the web of the block in the course above in a wall construction. the total thickness of the recess or indent is in the order of ¼″ generally starting out as a radius at the inside edge of one face shell to the inside edge of the opposite face shell's inside edge.
 7. The web offset lug dry-stack system as recited in claim 6, further comprising: a face shell, for the function of this element is for providing the wall surface . . . it attaches to the webs which incorporate the web offset lug . . . face shells may be beveled to provide a faux mortar joint appearance and/or may have head joints that are square or ship-lapped (ship-lapped is shown in FIG. 4).
 8. The web offset lug dry-stack system as recited in claim 6, further comprising: a web knock-out, for the function of this element is for providing for an easy way to insert horizontal steel reinforcement in the field . . . simply strike the knock-out area with a brick hammer to remove a section of the web.
 9. The web offset lug dry-stack system as recited in claim 6, further comprising: a corner block, for the function of this element is to provide a universal corner block that can be used to turn a left corner and a right corner. this element does not have or require raised lugs as it is held in place by interlocking with the raised lugs of the stretcher blocks below and adjacent to the stretcher blocks located at one end and at one side of the universal corner block.
 10. The web offset lug dry-stack system as recited in claim 7, further comprising: a web knock-out, for the function of this element is for providing for an easy way to insert horizontal steel reinforcement in the field . . . simply strike the knock-out area with a brick hammer to remove a section of the web.
 11. The web offset lug dry-stack system as recited in claim 7, further comprising: a corner block, for the function of this element is to provide a universal corner block that can be used to turn a left corner and a right corner. this element does not have or require raised lugs as it is held in place by interlocking with the raised lugs of the stretcher blocks below and adjacent to the stretcher blocks located at one end and at one side of the universal corner block.
 12. The web offset lug dry-stack system as recited in claim 8, further comprising: a corner block, for the function of this element is to provide a universal corner block that can be used to turn a left corner and a right corner. this element does not have or require raised lugs as it is held in place by interlocking with the raised lugs of the stretcher blocks below and adjacent to the stretcher blocks located at one end and at one side of the universal corner block.
 13. The web offset lug dry-stack system as recited in claim 10, further comprising: a corner block, for the function of this element is to provide a universal corner block that can be used to turn a left corner and a right corner. this element does not have or require raised lugs as it is held in place by interlocking with the raised lugs of the stretcher blocks below and adjacent to the stretcher blocks located at one end and at one side of the universal corner block.
 14. A web offset lug dry-stack system for a dry-stack structural building system for constructing masonry walls without the use of mortar with improved construction flexibility and structural strength. comprising: a web offset lug option a, for the function of this element is to provide alignment of the building blocks as they are stacked one row at a time until the appropriate wall height is reached. the raised lugs are located as an extension to the web at an angle (other than 90 degrees) to the face shells. the angle will vary based on the thickness of the block (face shell to face shell dimension) but is such that when the blocks are stacked the web of the lower and upper row of blocks forming a wall do not interfere with one another; a web offset lug option b, for the function of this element is the same as in web offset lug option a except that the raised lug is located adjacent to the web of the block that attaches and separates the two face shells of the block; a face shell, for the function of this element is for providing the wall surface . . . it attaches to the webs which incorporate the web offset lug . . . face shells may be beveled to provide a faux mortar joint appearance and/or may have head joints that are square or ship-lapped (ship-lapped is shown in FIG. 4); a lug detail, for the function of this element is to provide for easy interlocked stacking of building units one on top of the other so that the face shells of the wall are in alignment . . . also provides stability keeping the block from rotating or sliding in relation to one another . . . shape of the lug profile may be curved or angled. the lug may be raised from; a web knock-out, for the function of this element is for providing for an easy way to insert horizontal steel reinforcement in the field . . . simply strike the knock-out area with a brick hammer to remove a section of the web; a web recess, for the function of this element is to provide a additional clearance between the web of the block in the course below and the web of the block in the course above in a wall construction. the total thickness of the recess or indent is in the order of ¼″ generally starting out as a radius at the inside edge of one face shell to the inside edge of the opposite face shell's inside edge; and a corner block, for the function of this element is to provide a universal corner block that can be used to turn a left corner and a right corner. this element does not have or require raised lugs as it is held in place by interlocking with the raised lugs of the stretcher blocks below and adjacent to the stretcher blocks located at one end and at one side of the universal corner block. 